EV Liquid Cooling Layout for Parallel Power Electronics Heat Control
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Solution Overview
Problem
Conventional liquid cooling and air cooling systems are inadequate for effectively cooling the various components of electric vehicles, beyond just engine components.
Innovation Solution
A liquid cooling system for electric vehicles that includes a radiator, multiple coolant pumps, an inverter, an electric motor, a heat exchanger, an Onboard Battery Charger with a DC-to-DC converter, and a secondary DC-to-DC converter, all connected in parallel coolant path circuits to efficiently circulate coolant and manage heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional liquid cooling systems are used for engine components only, then engine cooling is adequate, but cooling for additional electric vehicle components (inverter, electric motor, battery charger, DC-to-DC converter) is insufficient
Solution Approach 1:
The liquid cooling system is designed to serve multiple functions by cooling various components including the engine, inverter, electric motor, battery charger, and DC-to-DC converter through a unified coolant circulation system with multiple pumps and radiators, thereby achieving universal cooling coverage across all heat-generating components
Solution Approach 2:
The cooling system is segmented into multiple independent coolant circulation circuits, each with its own coolant pump and radiator configuration, allowing targeted cooling of specific components (engine circuit, inverter circuit, motor circuit, battery charger circuit, DC-to-DC converter circuit) while maintaining overall system coordination
2Productivity
If multiple coolant pumps and parallel coolant path circuits are implemented, then cooling efficiency for multiple components is improved, but system complexity increases
Solution Approach 1:
The cooling system divides components into separate circulation circuits based on their cooling requirements, with each circuit having its own coolant pump and radiator configuration. This segmentation allows independent optimization of cooling flow for each component while maintaining manageable system complexity through modular design
Solution Approach 2:
Multiple coolant pumps are implemented to serve different circuits simultaneously, with each pump dedicated to specific components. This multi-functional approach enables efficient cooling of multiple heat-generating components in parallel, improving overall cooling productivity while distributing system complexity across independent subsystems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides efficient cooling for critical components of electric vehicles, enhancing their performance and reliability by effectively managing heat generation.
Implementation Method 1
a radiator to cool a coolant when the coolant flows through the radiator
Implementation Method 2
an inverter to be cooled by the coolant, an electric motor to be cooled by the coolant
Implementation Method 3
a heat exchanger through which the coolant and another liquid can circulate
Data Source
Figure 1
Figure 2
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AI summary
A liquid cooling system (1) includes a radiator (532) to cool a coolant when the coolant flows through the radiator (532), a first coolant pump (356L) to circulate the coolant, a second coolant pump (356R) to circulate the coolant, an inverter (6) to be cooled by the coolant, an electric motor (45) to be cooled by the coolant and connected to the inverter (6), a heat exchanger (381) through which the coolant and another liquid can circulate, an Onboard Battery Charger with a DC-to-DC converter (7) to be cooled by the coolant, and a secondary DC-to-DC converter (382) to be cooled by the coolant. The first coolant pump (356L) and the second coolant pump (356R) are each connected to the radiator (532).